UAS Automotive Technology
Course Syllabus
AUTO 152 – Brake Systems
Spring 2012 - Section J01
4 credits
Instructor:
Phone:
Email:
Ray Kaiser
(907)723-1002
kaiserray@yahoo.com
Course dates:
Wednesday, January 18 – Wednesday, May 2, 2012
Times:
Wednesday, 6:00 PM – 8:00 PM
Saturday, 9:00 AM – 1:00 PM
Location:
Technology Education Center, Room 216
Course Homepage:
http://www.uas.alaska.edu/online/
Course Description:
Theory, diagnosis, and repair of automotive brake systems.
Grading Method:
Letter
Prerequisites:
AUTO 121 or concurrent enrollment
Course Objectives: Upon successful completion of this course, the student will be able
to demonstrate ability to perform the following tasks as specified by NATEF
(National Automobile Technicians Education Foundation);
Task #
V.A.1
Priority
P-1
V.A.2
P-1
V.A.3
P-1
V.A.4
P-1
Task Description
Complete work order to include customer information, vehicle
identifying information, customer concern, related service
history, cause, and correction.
Identify and interpret brake system concern; determine
necessary action.
Research applicable vehicle and service information, such as
brake system operation, vehicle service history, service
precautions, and technical service bulletins.
Locate and interpret vehicle and major component identification
numbers.
V.B.1
P-1
V.B.2
P-1
V.B.3
P-1
V.B.4
V.B.5
P-1
P-2
V.B.6
P-1
V.B.7
V.B.8
P-2
P-2
V.B.9
V.B.10
P-1
P-3
V.B.12
V.B.13
V.C.1
P-1
P-1
P-1
V.C.2
P-1
V.C.3
V.C.4
P-1
P-1
V.C.5
V.C.6
P-2
P-2
V.C.7
P-1
V.D.1
P-1
V.D.2
P-1
V.D.3
P-1
V.D.4
P-1
V.D.6
P-1
Diagnose pressure concerns in the brake system using
hydraulic principles (Pascal’s Law).
Measure brake pedal height, travel, and free play (as
applicable); determine necessary action.
Check master cylinder for internal/external leaks and proper
operation; determine necessary action.
Remove, bench bleed, and reinstall master cylinder.
Diagnose poor stopping, pulling or dragging concerns caused
by malfunctions in the hydraulic system; determine necessary
action.
Inspect brake lines, flexible hoses, and fittings for leaks, dents,
kinks, rust, cracks, bulging or wear, tighten loose fittings and
supports; determine necessary action.
Replace brake lines, hoses, fittings, and supports.
Fabricate brake lines using proper material and flaring
procedures (double flare and ISO types).
Select, handle, store, and fill brake fluids to proper level.
Inspect, test, and/or replace metering (hold-off), proportioning
(balance), pressure differential, and combination valves.
Bleed and/or flush brake system.
Test brake fluid for contamination.
Diagnose poor stopping, noise, pulling, grabbing, dragging, or
pedal pulsation concerns; determine necessary action.
Remove, clean, inspect, and measure brake drums; determine
necessary action.
Refinish brake drum; measure final drum diameter.
Remove, clean, and inspect brake shoes, springs, pins, clips,
levers, adjusters/self-adjusters, other related brake hardware,
and backing support plates; lubricate and reassemble.
Inspect and install wheel cylinders.
Pre-adjust brake shoes and parking brake; install brake drums
or drum/hub assemblies and wheel bearings.
Install wheel, torque lug nuts, and make final checks and
adjustments (drum brakes)
Diagnose poor stopping, noise, pulling, grabbing, dragging or
pulsation concerns; determine necessary action.
Remove caliper assembly; inspect for leaks and damage to
caliper housing; determine necessary action.
Clean and inspect caliper mounting and slides/pins for
operation, wear, and damage; determine necessary action.
Remove, inspect, and replace pads and retaining hardware;
determine necessary action.
Reassemble, lubricate, and reinstall caliper, pads, and related
hardware; seat pads and inspect for leaks.
V.D.7
P-1
V.D.8
V.D.9
V.D.10
V.D.11
V.D.12
P-1
P-1
P-1
P-3
P-1
V.D.13
P-2
V.E.1
V.E.2
V.E.3
P-2
P-1
P-1
V.E.5
V.F.1
P-3
P-1
V.F.2
P-1
V.F.3
P-2
V.F.4
P-1
V.F.6
V.F.7
V.F.8
V.G.1
P-1
P-1
P-1
P-1
V.G.2
P-2
V.G.5
V.G.8
P-1
P-3
V.G.10
P-3
Clean, inspect, and measure rotor thickness, lateral runout, and
thickness variation; determine necessary action.
Remove and reinstall rotor.
Refinish rotor on vehicle; measure final rotor thickness.
Refinish rotor off vehicle; measure final rotor thickness.
Retract caliper piston on an integrated parking brake system.
Install wheel, torque lug nuts, and make final checks and
adjustments (disc brakes).
Check brake pad wear indicator system operation; determine
necessary action.
Test pedal free travel; check power assist operation.
Check vacuum supply to vacuum-type power booster.
Inspect the vacuum-type power booster unit for leaks; inspect
the check valve for proper operation; determine necessary
action.
Measure and adjust master cylinder pushrod length.
Diagnose wheel bearing noises, wheel shimmy, and vibration
concerns; determine necessary action.
Remove, clean, inspect, repack, and install wheel bearings and
replace seals; install hub and adjust bearings.
Check parking brake cables and components for wear, binding,
and corrosion; clean, lubricate, adjust or replace as needed.
Check parking brake and indicator light system operation;
determine necessary action.
Replace wheel bearing and race.
Inspect and replace wheel studs.
Remove and reinstall sealed wheel bearing assembly.
Identify and inspect electronic brake control system
components; determine necessary action.
Diagnose poor stopping, wheel lock-up, abnormal pedal feel,
unwanted application and noise concerns associated with the
electronic brake control system; determine necessary action.
Bleed the electronic brake control system hydraulic circuits.
Diagnose electronic brake control system braking concerns
caused by vehicle modifications (tire size, curb height, final
drive ratio, etc.).
Describe the operation of a regenerative braking system.
Textbook:
Automotive Brake Systems (Fifth edition) by James D. Halderman. This
textbook comes packaged with a worktext, and is available in the bookstore in
the Mourant building at the main campus.
Materials needed for class:



Safety glasses (required) – safety glasses will be worn at all times in the
Automotive Lab. You can purchase a set of approved UVEX safety glasses at the
campus bookstore. Note that there are two types available; regular and ones made
to go over eyeglasses.
Coveralls (optional – how dirty do you want to get?)
Personal padlock (optional) – personal lockers are available to you, but locks must
come off and the locker emptied at the end of the semester.
Note: You will NOT be required to purchase hand tools to participate in this class. All
tools will be provided for you. It is important to note, however, that you are expected to
treat the program’s hand tools with respect, and be sure to return them as you found
them. This means wiping them clean and making sure they go back in their proper
place.
Grading:
Every student needs to know exactly how they will be graded during the
course. There are four areas that make up your grade in AUTO 152:
1. 20% of your grade is determined by attendance in lab and classroom sessions.
Typically, I will assign two points per session. A student will receive one point if they
are on time for class, and one more will be assigned if they stay until the end of class.
2. 40% of your grade is determined by completion of lab assignments. Specific skills
are taught during the lab sessions of the class and you will receive credit for these by
completing the lab worksheets.
3. 40% of your grade is based on your performance on quizzes and the midterm and
final exams.
Grades will be assigned based on the following percentages:
A
AB+
B
BC+
C
CD+
D
DF
93-100%
90-92%
86-89%
83-85%
80-82%
76-79%
73-75%
70-72%
66-69%
63-65%
60-62%
60% and below
The bottom line is, you cannot do well unless you come to class consistently. Coming
late or not at all is the quickest way to put yourself in the hole.
Online Gradebook: Student grades are maintained in a secure online environment.
You can access your current grade and the scores of all assignments by going to
the course home page and entering your personal access code under
“Assignments.”
Homework: You are assigned homework for every class meeting. For instance, if the
content of meeting three was covered during one session, it is expected that you
will do the homework for that meeting and have it ready for class the following
meeting. Answer keys for the homework will be available at the course
homepage at UAS Online.
While no credit is extended for completion of the homework, your performance
on quizzes and exams will be in proportion to your effort in completing the
homework assignments!
Conduct in the lab: The Auto lab is an industrial environment and safety is the
number one priority. Having said that, horseplay is strictly forbidden in the
lab. Students are expected to conduct themselves in a professional, courteous
manner at all times. Many of the resources must be shared and everyone is
expected to cooperate with others as best they can.
Class evaluations: You will be given the opportunity to write your own evaluation of
this class on UAS Online during the last three weeks that we meet. This is a big
favor you are doing for me, as it helps me determine how to make the class
better. If you don’t like something that is being done, please say so, but also
make a suggestion for how to make it better.
Course drops/withdrawals: The last day to drop this class is January 31. The last day
to withdraw from this class is April 9.
Please stay in touch and let me know if you cannot make it to a particular class.
If I haven’t seen or heard from you in three weeks, I will check to see if you have
dropped. If you haven’t, I will initiate a withdrawal to prevent my having to assign
you an “F” grade.
Course Schedule:
Meeting
Meeting 1
Jan. 18
Jan. 21
Meeting 2
Jan. 25
Jan. 28
Meeting 3
Feb. 1
Feb. 4
Meeting 4
Feb. 8
Feb. 11
Meeting 5
Feb. 15
Feb. 18
Meeting 6
Feb. 22
Feb. 25
Meeting 7
Feb. 29
Mar. 3
Meeting 8
Mar. 7
Mar. 10
Mar. 14
Mar. 17
Meeting 9
Mar. 21
Mar. 24
Meeting 10
Mar. 28
Mar. 31
Meeting 11
April 4
April 7
Lecture Topic
(Wednesday)
Shop safety
Lab/Demonstration
(Saturday)
Shop safety orientation
Homework
Shop safety quiz
Brake system
components and
principles
Quiz #1
Brake hydraulic
systems
Brake system
component ID and
inspection
Read ch. 3&4,
complete all ch. quiz
Inspect hydraulic
systems, check proper
operation & component
ID
Brake line fabrication
and brake system
bleeding
Read ch. 5&6 ch. 5
review #3 & all ch.
quiz- ch. 6 review #2 &
all ch. quiz
Read ch. 7&8, ch. 7
review #3,4,5 & all ch.
quiz- ch. 8 review #1,2
& all ch. quiz
Read ch. 9, complete
all review and ch. quiz
Quiz #2
Brake lines, fluids, and
bleeding- line
fabrication
Quiz #3
Wheel bearings
diagnosis and service
Quiz #4
Drum brake
components, diagnosis
and service
Quiz #5
Disc brake
components, diagnosis
and service
Midterm Exam
Spring Break
(no classes)
Parking brake & power
brake systems
operation & service
Quiz # 6
Machining brake
drums & rotors
Quiz #7
ABS components and
operation
Wheel bearing and
race diagnosis,
inspection and
replacement
Drum brake inspection,
diagnosis and repair
Disc brake inspection,
diagnosis and repair
Read ch. 1&2,
complete all ch. quiz
Read ch. 10&11,
complete all ch. quiz
for both
TBA
Read ch. 12&13, ch.
12 all ch. quiz- ch. 13
review #3 & all ch. quiz
Study for Midterm
HAVE FUN!!
Parking brake service
& adjustment, power
brake system
inspection & service
Machining
demonstration and lab
Read ch. 14&16, ch 14
all review & ch. quizch. 16 review 2,4 & all
ch. quiz
Read ch. 15, complete
all ch. quiz
ABS component ID &
Inspection
Read ch. 18, complete
all review & ch. quiz
Meeting 12
April 11
April 14
Meeting 13
April 18
April 21
Meeting 14
April 25
April 28
Meeting 15
May 2
Quiz #8
ABS diagnosis and
service
Quiz #9
Regenerative braking
systems & electronic
stability control
Quiz #10
Review
WSS testing & ABS
diagnostics
Read ch. 20, review #
1,2 & all ch. quiz
Electronic stability
control scan data
retrieval & make up
Read ch. 17&21, ch.
17 all ch. quiz- ch. 21
review #4, all ch. quiz
Finish lab assignments
Study for final
Final exam
(comprehensive).
Cleanup lab and
personal belongings.